From Here to Construction

1
From Here to Construction

• Michael Hebert
• UC Irvine
• March 9, 2004
• NSF RSVP Review

2
Outline

• The Importance of, Status of, and Plans for the
  Magnet Acquisition
• A Review of each Level 2 WBS task examining
  readiness, resource needs, and schedule to get
  from here to construction
• Summary of the proposal budget, schedule of
  events that carries us to a construction start

3
Opening Comments

• We are proposing to continue the design phase of
  the magnet system in this grant period, including
  funding four months of the estimated one year
  magnet engineering design. We dont believe we
  can wait for MRE-FC funding for the engineering
  design effort. This allows us to maintain the
  momentum on the critical path system. The
  alternative could mean more than a years delay
  in completing the project.
• We have not requested support for every task that
  we could start now due to the limited
  availability of funding
• We will make major progress on every subsystem,
  in addition to the magnets in particular we will
  greatly increase the engineering effort going
  into MECO

4
MECO Collaboration

• Institute for Nuclear Research, Moscow
• V. M. Lobashev, V. Matushka,
• New York University
• R. M. Djilkibaev, A. Mincer,
  P. Nemethy, J. Sculli, A.N. Toropin
• Osaka University
• M. Aoki, Y. Kuno, A. Sato
• University of Pennsylvania
• W. Wales
• Syracuse University
• R. Holmes, P. Souder
• College of William and Mary
• M. Eckhause, J. Kane, R. Welsh

• Boston University
• J. Miller, B. L. Roberts
• Brookhaven National Laboratory
• K. Brown, M. Brennan, G. Greene,
• L. Jia, W. Marciano, W. Morse,
  Y. Semertzidis, P. Yamin
• University of California, Irvine
• M. Hebert, T. J. Liu, W. Molzon, J.
  Popp, V. Tumakov
• University of Houston
• Y. Cui, E. V. Hungerford,
  N. Klantarians, K. A. Lan
• University of Massachusetts, Amherst
• K. Kumar

5
Features of MECO

• 1000fold increase in m beam intensity over
  existing facilities
• High Z target for improved pion production
• Axially-graded 5 T solenoidal field to maximize
  pion capture

Superconducting Solenoids
Muon Beam
1 T
1 T
Calorimeter
2 T
Straw Tracker
Stopping Target Foils
Proton Beam

• Curved transport selects low momentum m-
• Muon stopping target in a 2 T axially-graded
  field to improve
  conversion e- acceptance
• High rate capability e- detectors in a constant 1
  T field

2.5 T
5 T
Pion Production Target
6
MECO MREFC Critical Path
The magnets directly determine when we finish
construction (stop spending MRE money) and start
full-scale data taking
7
Magnet Progress

• As a reminder
• Conceptual Design completed on FY01 funds, very
  favorably reviewed
• Commercial procurement endorsed by Magnet
  Acquisition Panel
• Three Industrialization Studies completed using
  FY02 funds
• Insulation system for the coils and joints
  recommended epoxy and other material choices for
  radiation hard fabrication
• Winding, impregnation logistics, fabrication cost
  and schedule concluded that the magnets can be
  built commercially within the nominal 41 month
  schedule for a price consistent with our
  expectations
• Refrigerator/liquefier refurbish or buy new
  recommendation
• Procurement activities (more details in a moment)
• Magnet Acquisition Plan drafted
• Magnet Statement of Work and Technical
  Specification-incorporating BNL and LLNL comments
• RFP being drafted
• First meeting with potential vendors held at MT18
  Conference in October

8
Magnet Progress

• Field error analyses and other studies also
  supported by FY03 funds
• Updated structural models of PS, TS and DS
  magnets from CDR to evaluate effects of modulus
  and coefficient of thermal contraction variations
  and deadweight effects.
• New PS iron return yoke and pole piece
• Revised PS coil builds
• DS includes new iron pole piece
• TS Stiffer and wider cryostat pedestals
• Relocated horizontal support in downstream TS to
  accommodate DS pole
• TS Cryostat shell modeling

9
Magnet Progress
TS
PS
DS

• Created mandrel and mandrel assembly drawings
  with tolerances and verified manufacturability
  with commercial fabrication shops
• Preliminary conclusions
• Field errors due to manufacturing tolerances and
  material property variations appear manageable in
  PS and DS TS analysis underway
• DS field errors are driven by the mandrel and
  assembly tolerances. Field analysis is underway
  by UCI.
• PS field errors are driven by the mandrel and
  assembly tolerances but the field spec in the PS
  region is forgiving.
• TS structural model is most complicated. Awaiting
  updated results.
• Final results will be reflected in the final RFP
  documents

10
Draft Magnet Acquisition Plan

• Draft exists and will be submitted for NSF
  approval shortly
• Establishes roles of all major players
• MIT Subsystem Manager and COTR, chairs bid
  review panel
• LLNL provides Contracting Officer backed by the
  experience of the whole NIF contracting team
• UCI provides source selection official, funds
  vendor contract
• NYU provides MREFC funds to UCI for all MECO
  effort concurs with UCI source selection
• BNL provide site access and interface
  information, operational requirements via MDMG,
  participates in bid review panel
• Summarizes estimated design, construction, and
  life cycle costs
• Discusses commercial, technical, manufacturing,
  and ESH risks
• Lays out the procurement plan (next slide)

11
Magnet Procurement Plan

• Assumes the final design, fabrication,
  installation and acceptance testing will be
  performed by a commercial vendor or a team of
  vendors.
• Identifies method as Best Value Source Selection
• Identifies firms have required capabilities or
  known to have an interest
• ACCEL
• Alahlam Ltd.
• Ansaldo Superc
• Babcock Noell Nuclear GmbH
• Cryogenic Ltd.
• General Atomics
• Hitachi
• Establishes a fixed price, contract as the
  preferred option allows for industry feedback
  at draft RFP stage
• Discusses possibility of splitting out high cost
  risk interface items and/or installation
• Establishes management information requirements
  reporting, QA, etc.

• Mitsubishi Electric Corp.
• Oxford Instruments
• Sigmaphi
• Space Cryomagnetics
• Toshiba
• Wang NMR Inc.

12
Draft Magnet Acquisition Schedule

• This list assumes an uninterrupted flow of funds,
  i.e. an FY05 MREFC start or continuing RD
  support for the engineering design in 05

13
Baseline Information Today

• MECO WBS exists, but needs extensive revision.
  This is job one.
• Reference Design Documents listing design and
  interface parameters exist for some systems.
  Will need initial versions for the remaining
  major systems as part of completing 1 above.
• WBS Dictionary again exists, but must be
  revised in conjunction with 1.
• Cost Database system, including risk assessment
  handling, is loaded with the preceding info as of
  Jan 2003. As 1 3 above evolve, we will
  incorporate the changes.
• Cost Book exists, but is sparsely populated
  with solid backup material.
• Subsystem schedules exist in detail for the
  magnets and for the proton beamline work.
  Schedules for all other subsystems exist, but in
  coarser grain.
• Technical Design Report exists only in draft
  form, but has not been updated since June 2001.
  Details needed for engineering efforts have
  instead been captured in the Reference Design
  Documents mentioned above
• Project Management Plan exists but will require
  revision

14
Near Term Milestones

• Preparation for a baseline review in July

Note that new hires under this proposal are not
going to be on board soon enough to contribute
much to the baselining effort
15
Reviewing Each L2 WBS

• The following slides review each MECO level 2 WBS
  task
• Current status and recent development progress
• Specific needs for baselining
• Preparation for construction
• Near term schedule of activities
• Costs listed are those included in the pending
  proposal

16
WBS 1.4 Solenoids

• Resources Needed to Baseline - 558k
• Support for MIT PSFC to continue in their
  oversight role and update cost information for
  the baseline. This number includes the SSM and
  additional FTEs to support the engineering design
  effort for the four months covered under this
  grant (this actually extends beyond establishing
  the baseline)
• Starting the Engineering Design - 1545k
• Four months of design effort by an estimated team
  of 22 engineers, designers, and managers working
  for the magnet construction vendor
• Cost risk reduction studies at MIT and component
  fabrication vendors
• Contracting Officer support at LLNL
• Part-time support for magnet and cryogenics
  experts at BNL to participate in Magnet Design
  Management Group, providing facilities interface
  and safety information to magnet contracting team

17
WBS 1.4 Solenoids
Draft RFP Released This Month
Final RFP Rel. Sept. 04
Engineering Design Commences in March 05
18
WBS 1.1 AGS Modifications, Studies

• Current Status
• No beam studies since 1998 nor hardware design
  efforts
• Hardware consists of a new AC dipole similar to
  an existing magnet and new pulser and power
  supply for the existing stripline kicker,
  requirements based on existing studies info
• New concerns about ALARA limits, available
  running time, and aperture limits
• Resources Needed to Baseline - 0
• Extensive beam studies will be required to
  achieve MECO running conditions. Nonetheless we
  have omitted this from the proposal to direct
  funds elsewhere. Our plan is conduct these
  studies with MREFC funds.
• AGS RF experts are needed to spec the hardware,
  although their time is often saturated solving
  RHIC problems

19
WBS 1.1 AGS Modifications, Studies

• Preparation for efficient use of MREFC funds -
  151k
• Design of AC dipole, new pulsers for AGS Kicker
  allow for construction and installation in 06
  allowing for extinction measurement in 06/7 run

This is a Final Design Review, i.e. we are ready
to cut metal on the AC Dipole and procure of
pulsers and power supplies for the Kicker in
October 04
20
WBS 1.2 Proton Beamline

• Current Status
• Some off-project effort by C-AD physicists
  developing beamline optics to establish aperture
  limits and hardware requirements
• Preliminary shielding design and AGS floor layout
  in A line by C-AD engineers
• RF Modulated Magnet (RFMM) stripline and cavity
  geometry studies at UCI
• Resources required to baseline this effort - 37k
• Beamline Optical Design a prerequisite for all
  other activity in the beamline, establishes which
  magnets and instrumentation are needed note
  this was previously assumed to be an off-project
  research effort, now at our expense
• Support for AGS Liaison Engineer is covered in
  WBS 1.11
• Preparation for efficient use of MREFC funds -
  447k
• Shielding Design Start this long lead time task
  now to begin labor (and ) intensive beamline
  refurbishment in 05
• Instrumentation Controls design Allows for
  procurement of instrumentation needed for beam
  tests in 06/7
• RF Modulated Magnet conceptual design Allows
  for prototype construction in 05, installation
  in 06 shutdown, testing in 06/7

21
WBS 1.2 Proton Beamline
Extracted beam parameters determined in August
RFMM design complete in January, prototype awaits
MREFC funds
22
WBS 1.3 Target Heat Shield

• Current Status
• Initial version of Reference Design exists
• Extensive simulation, design, and testing of
  water-cooled prototypes at UCI
• Heat Shield conceptual design effort begun at
  C-AD with FY03 funds
• Resources required to baseline this effort - 57k
• Identify a long term subsystem manager talking
  to a candidate now
• Extend Heat Shield design work to full conceptual
  design
• Develop conceptual design of target cooling
  
  and handling and storage systems
• Preparation for efficient use of
  
  MREFC funds - 35k
• Extend target mockup tests to
  
  realistic heat loads
• Fabricate a test setup for later beam
  
  testing

23
WBS 1.3 Target Shield
Heat Shield and Target Remote Handling and
Storage System Designs complete in July
Production target design review follows prototype
beam testing on MREFC funds complete Jan 06
24
WBS 1.5 Muon Beamline

• Current Status
• Vacuum, Collimator, m Beam Stop, n Absorber
  Reference Designs exist
• Vacuum window conceptual design completed on FY02
  funds
• Vacuum, m Beam Stop, and Absorber engineering
  efforts ongoing at BNL
• Vacuum studies, Beam Stop and Absorber
  optimization at UCI
• Resources required to baseline - 71k RD
• Complete BNL design work to provide detailed
  magnet interface information and cost information
• Preparation for efficient use of MREFC funds
• The primary motive to push these designs is to
  develop the magnet interface info. With that in
  hand we do not need greater detail before MREFC
  start

25
WBS 1.5 Muon Beamline
26
WBS 1.6 Tracker

• Current Status
• Two tracker geometry options remain under
  consideration
• Longitudinal geometry with 3000 3m long straws
  oriented nearly coaxial with the DS and 23000
  capacitively coupled cathode strips for axial
  coordinate measurement
• Transverse geometry with 13000 1m straws,
  oriented transverse to the axis of the DS,
  readout at both ends
• Two readout options under consideration as well
• Digitizing inside the DS cryostat or passing
  analog signals out and digitizing remotely

Longitudinal Tracker
27
Tracker RD

• Studies provide input to select geometry and
  readout architecture
• Full-length longitudinal vane prototype remains a
  work in progress at Houston as mechanical
  stability and straw bonding issues are resolved
• Electronics design and prototype work at Houston
  has progressed to testing prototype preamplifier,
  digitizer, and controller boards as a system
  using the current (outdated) version of BaBars
  Elefant chip with very promising results
• Simulations of both the longitudinal and
  transverse geometries continue, indications are
  that either geometry might work from a physics
  standpoint

28
WBS 1.6 Tracker

• Resources required to baseline this effort - 0
• We know enough about the tracker options to
  reliably cost them without significantly more
  engineering
• Preparation for efficient use of MREFC funds -
  414k
• Mechanical and signal tests with full length vane
  prototype
• Revise the BaBar Elefant chip (from 0.8 mm to
  0.25 mm technology) for MECO use a joint
  venture between Houston and LBNL estimated to be
  a one year design task, we are proposing to fund
  six months of it under this grant
• Full-time mechanical engineering support funded
  under WBS 1.11
• Design and prototype a low mass manifold

29
WBS 1.6 Tracker
Geometry Decision in November
30
WBS 1.7 Calorimeter

• Current Status
• Bench tests of PbWO4 crystals cooled to 23 C
  and large area avalanche photodiodes continue at
  NYU using electronics designed and built in house
• Indications are that this material will meet MECO
  resolution requirements, demonstrating 20-30
  photo e-/MeV (as compared with CMS 5 pe/MeV)
• We need to verify the system performance via beam
  tests of an 8?8 crystal array

• If true we can sharply reduce the contingency on
  the Calorimeter that covered the possibility of
  using BGO crystals
• Further it appears that we can make use of fewer
  (larger) crystals allowing reductions in APD, and
  associated HV and readout channel counts (1152
  crystals vs. 2000 originally)

Estimated
31
WBS 1.7 Calorimeter

• Resources required to baseline this effort - 0
• We know enough to baseline this system now
• Preparation for efficient use of MREFC funds -
  421k
• Funds for construction of an 8 x 8 prototype
  crystal array including photodetectors, cooling,
  calibration, readout electronics, vacuum system
  and test vessel
• Funds for beam testing
• Contribution of the Chief Electrical Engineer
  (funded in WBS 1.11) to the design of readout and
  trigger electronics
• In addition to verifying the primary approach
  with an appropriate scale prototype, this
  advances the design effort and should allow for
  an early start to anticipated lengthy crystal and
  APD procurement phases

32
WBS 1.7 Calorimeter
Crystal Material Selected
Calorimeter Conceptual Design Review in June 05
33
WBS 1.8 Cosmic Ray Shield

• Current Status
• Extensive testing at William Mary have
  established a combination of scintillator,
  wavelength shifter, and multi-anode PMT that will
  meet MECOs 99.9 cosmic ray veto efficiency
  requirement
• Extrusion of 100 4m slats this summer at Itasca
  following MINOS lead
• Test slats will be assembled into a prototype
  module this Fall
• Resources required to baseline this effort - 53k
• Mechanical engineering support for William
  Mary, either locally, or at BNL to assist in
  developing a conceptual design for the counters
  and particularly their installation beneath the
  detector solenoid
• Preparation for efficient use of MREFC funds -
  90k
• Materials and shop time to produce prototype
  module components
• Student labor for bonding WLS fibers into slats,
  module assembly and testing at William Mary

34
WBS 1.8 Cosmic Ray Shield
Veto Counter Conceptual Design Review in Sept 04
35
WBS 1.9 Trigger DAQ

• Current Status
• No engineering has gone into the Trigger or DAQ
  to date, although this has the potential to be a
  long lead time item
• Resources required to baseline this effort - 42k
• A fraction of the support for BUs Electronics
  Design Facility (EDF) will be necessary to
  develop at least a sketch level design for the
  system and cost it out
• Preparation for efficient use of MREFC funds -
  241k
• Support for the completion of EDFs design effort
  
• Components, prototype boards, test equipment
• Allows for testing of trigger hardware as part of
  the Calorimeter and Tracker test beam studies

36
WBS 1.9 Trigger DAQ
Trigger and DAQ Hardware Conceptual Design
Review in July 05
37
WBS 1.10 Infrastructure

• Reminder that Infrastructure for MECO presently
  refers to the counting house, electronics hut,
  and compressor building for the refrigerator /
  liquefier
• Current Status
• Existing structures have been identified to serve
  as counting house and compressor building,
  although they will require some clean out and may
  require refurbishment of power and other services
• Electronics enclosure must be constructed, but is
  small and simple
• Resources required to baseline this effort - 0
• The construction cost and schedule estimation
  effort on the part of the AGS liaison engineer is
  supported under WBS 1.11
• Required design input information is funded under
  WBS 1.4 1.7
• Preparation for efficient use of MREFC funds - 0
• This task is not on the critical path, nor are
  detailed designs required to make efficient use
  of MREFC funding in the first year, thus once we
  have the information required for baselining, we
  will be set until the project starts.

38
WBS 1.11 Management

• Current Status
• Full time PM on board
• No other project office personnel
• Project documentation described earlier
• Resources required to baseline this effort -
  300k
• Ongoing PM support
• Support for AGS Liaison staff
• Preparation for efficient use of MREFC funds -
  446k
• Chief Mechanical Engineer This hire is needed
  for integration as we approach construction and
  to contribute to the pool of engineering talent
  designing MECO
• Chief Electrical Engineer the same statement
  applies here
• Cost and Schedule Manager The PM cannot
  continue in this role as we gear up for
  construction, so this individual should be on
  board well before the start of MREFC funding to
  setup shop and establish procedures

39
WBS 1.10 1.11 Schedules
Updating the information needed for baselining is
straightforward. Detailed designs await MREFC
funds as this is not a place that we need to
spend money early.
These time estimates could prove optimistic
40
Proposal MECO Budget 1
41
Proposal MECO Budget 2